Electrical devices, such as safety disconnect switches, are often used in industrial applications to selectively couple loads, such as machinery, motors, lights, fans, pumps, generators and the like, to power sources. These electrical devices are designed to operate, and often do operate, in harsh conditions such as wet, dusty, or corrosive environments. As a result, the electrical devices and any device coupled thereto require frequent manual inspection and maintenance to ensure safe and effective operation. In many instances, maintenance problems are not detected until after damage has occurred. Further, routine manual inspections require a significant investment in manhours. As a result, electrical devices such as, for example, safety disconnect switches and mechanical interlocks, may be provided having components that can monitor operating conditions of the electrical device, or any device coupled thereto, while also being connected to remote devices to provide remote monitoring of the electrical device to facilitate more efficient preventative maintenance.
Shortcomings of the prior art are overcome and additional advantages are provided through the provision of electrical devices, such as electrical switch devices. In one embodiment of an electrical switch device for supplying power to a load, the electrical switch device includes (i) a printed circuit board (PCB), the PCB comprising a communication circuit configured to communicate with a remote device and a processing circuit; (ii) a handle configured to rotate between a first position and a second position; (iii) a load switch arranged and configured to open and close to selectively supply power to the load; (iv) a magnet; and (v) a magnetic sensor configured to sense a magnetic field emanating from the magnet. In such an electrical switch device, rotation of the handle between the first position and the second position causes rotational motion of at least one of the magnet and the magnetic sensor, the rotational motion repositions the magnet and the magnetic sensor relative to each other, and the magnetic sensor is configured to sense the repositioning and output a signal to the processing circuit indicative of a position of the handle.
Rotation of the handle between the first position and the second position may cause the load switch to open and close. For instance, rotation of the handle can cause rotation of a component that opens and closes the load switch.
In embodiments, the electrical switch device further includes a component that is configured to rotate based on rotation of the handle between the first position and the second position, where the magnet is coupled to the component. The component may be a handle shaft, and the magnet may be disposed at least partially embedded in the handle shaft. Rotation of the handle between the first position and the second position may cause rotational motion of the magnet to move the magnet closer to, or farther from, the magnetic sensor.
Additionally or alternatively, the electrical switch device can include a stop plate disposed between the magnet and the magnetic sensor. The stop plate can include an opening, and when the handle is positioned in the first position, the magnet may be closer to the opening of the stop plate than when the handle is positioned in the second position. Based on the handle being in the first position, the magnet may be in one position that is at least partially aligned with the opening of the stop plate, and based on the handle being in the second position the magnet may be in another position that is out-of-alignment with the opening of the stop plate. In embodiments, the magnetic sensor is configured to sense the magnetic field emanating from the magnet in the one position based on the handle being in the first position, where the intensity of the magnetic field emanating from the magnet as sensed by the magnetic sensor is greater when the handle is in the first position and the magnet is in the one position as compared to when the handle is in the second position and the magnet is in the another position. The one position, in which the magnet is at least partially aligned with the opening of the stop plate, can correspond to an OFF position in which the load switch is open, and the another position, in which the magnet is out-of-alignment with the opening of the stop plate, can correspond to an ON position in which the load switch is closed to provide the power to the load. In embodiments, the stop plate includes material with a shielding property (such as steel) that shields the magnetic field sensor from the magnetic field emanating from the magnet when the handle is positioned in the second position, and the opening of the stop plate is positioned and configured such that when the handle is positioned in the first position, the magnetic field sensor senses the magnet field emanating from the magnet passes through the opening in the stop plate.
Additionally or alternatively, the electrical switch device can include a stacked board arrangement in which the magnet, the magnetic sensor, and the PCB are provided in a stacked configuration coupled together and at least partially enclosed in a cover of the electrical switch device.
In embodiments, the load switch is configured to accept a plurality of input power phase conductors. The electrical switch device can further include a current sensor configured to sense a respective level of current through each phase conductor of the plurality of input power phase conductors and communicate, via a PCB of the current sensor, the sensed respective level of current through each phase conductor to another component of the electrical switch device.
Additionally, in accordance with embodiments described herein, an electrical device is provided that includes a cover subassembly configured for operatively coupling with a handle. The cover subassembly includes (i) a printed circuit board (PCB), the PCB comprising a communication circuit configured to communicate with a remote device and a processing circuit; (ii) a magnet; and (iii) a magnetic sensor configured to sense a magnetic field emanating from the magnet. In such an electrical switch device, the cover subassembly is configured such that rotation of the handle between the first position and the second position causes rotational motion of at least one of the magnet and the magnetic sensor, the rotational motion can reposition the magnet and the magnetic sensor relative to each other, and the magnetic sensor is configured to sense the repositioning and output a signal to the processing circuit indicative of a position of the handle.
In embodiments, the cover subassembly further includes a component configured to rotate based on rotation of the handle between the first position and the second position, where the magnet is coupled to the component. The component may be a handle shaft, for instance, and the magnet may be disposed at least partially embedded in the handle shaft.
The cover subassembly may be configured such that rotation of the handle between the first position and the second position causes rotational motion of the magnet to move the magnet closer to, or farther from, the magnetic sensor.
In embodiments, the cover subassembly further includes a stop plate disposed between the magnet and the magnetic sensor. The stop plate can include an opening. The cover subassembly may be configured such that when the handle is positioned in the first position, the magnet is closer to the opening of the stop plate than when the handle is positioned in the second position.
Additionally or alternatively, the cover subassembly may be configured such that, based on the handle being in the first position, the magnet is in one position that is at least partially aligned with the opening of the stop plate, and, based on the handle being of the second position, the magnet is in another position that is out-of-alignment with the opening of the stop plate.
In embodiments, the magnetic sensor is configured to sense the magnetic field emanating from the magnet in the one position based on the handle being in the first position, where the intensity of the magnetic field emanating from the magnet as sensed by the magnetic sensor is greater when the handle is in the first position and the magnet is in the one position as compared to when the handle is in the second position and the magnet is in the another position. The one position, in which the magnet is at least partially aligned with the opening of the stop plate, can correspond to an OFF position, and the another position, in which the magnet is out-of-alignment with the opening of the stop plate, can correspond to an ON position. In embodiments, the stop plate includes material with a shielding property (such as steel) that shields the magnetic field sensor from the magnetic field emanating from the magnet when the handle is positioned in the second position, and the opening of the stop plate is positioned and configured such that when the handle is positioned in the first position, the magnetic field sensor senses the magnet field emanating from the magnet passes through the opening in the stop plate.
Additionally or alternatively, the cover subassembly can include a stacked board arrangement in which the magnet, magnetic sensor, and the PCB are provided in a stacked configuration coupled together and at least partially enclosed in a cover of the cover subassembly.
In embodiments, the electrical also includes the handle, a base subassembly that includes a DIN rail and a load switch coupled to the DIN rail, the load switch arranged and configured to open and close to selectively supply power to a load, and a switch rod coupling the load switch to the cover subassembly. Rotation of the handle between the first position and the second position can cause rotation of the switch rod to open and close the load switch.
In embodiments, the load switch is configured to accept a plurality of input power phase conductors. The electrical switch device can further include a current sensor configured to sense a respective level of current through each phase conductor of the plurality of input power phase conductors and communicate, via a PCB of the current sensor, the sensed respective level of current through each phase conductor to another component of the electrical switch device.
Additional features and advantages are realized through the concepts described herein.
Aspects described herein are particularly pointed out and distinctly claimed as examples in the claims at the conclusion of the specification. The foregoing and other objects, features, and advantages of the disclosure are apparent from the following detailed description taken in conjunction with the accompanying drawings in which:
Described herein are safety disconnect switches (collectively “electrical switch devices”), components thereof, and related electrical devices for informing of status relating to supply of electricity to connected equipment. A safety disconnect switch may also be referred to herein as an “electrical switch device”, “disconnect device”, “electrical disconnect”, or just “disconnect”, and may or may not incorporate separate mechanical interlock features as plug-connector components.
Slider plate 170, latch spring 180 and interlock latch 160 may collectively form an interlock latch assembly. In use, the interlock latch assembly is selectively movable between a first position and a second position. The interlock latch assembly is arranged and configured to be operatively associated with the connector 120 and the external handle assembly 140 so that when the interlock latch assembly is in the first position, the interlock latch assembly prevents rotation of the external handle assembly 140, and when the interlock latch assembly is in the second position, the interlock latch assembly permits rotation of the external handle assembly 140. In one embodiment, the interlock latch assembly is movable between the first position and the second position via insertion of the plug into the connector 120. That is, insertion of the plug into the connector 120 contacts and moves the interlock latch assembly from the first position to the second position.
Mechanical interlock 100 also includes a DIN rail 132 for receiving the load switch 130, and a contact carrier bracket 102 and adapter 104 for coupling the connector 120 relative to the enclosure. The mechanical interlock 100 may also include one or more printed circuit boards (PCBs) such as, for example, PCB 106 coupled to the contact carrier bracket 102.
As noted, the enclosure includes base 112 and cover 114, although it is envisioned that the enclosure may be manufactured from a greater or fewer number of portions. The enclosure may be manufactured from any suitable material including, for example, plastic, metal, or the like.
Given the tight space constraints within the enclosure and the number of components being positioned therein, assembly of the mechanical interlock 100 can be challenging. For example, wiring the connector 120, the internal load switch 130, and the PCB 106 can be challenging when those components are positioned within the side walls of the enclosure (e.g. walls of base 112).
To facilitate easier assembly, the mechanical interlock 100 includes a plate, carrier, platform, chassis, or the like (collectively referred to herein as a base plate without the intent to limit) 108. In use, the base plate 108 is arranged and configured to receive one or more components thereon so that the components can be initially coupled to the base plate 108 and wired to each other without the space constraints of the enclosure base 112. Thereafter, the base plate 108 including the components coupled thereon can be positioned within the enclosure and the base plate 108 can be coupled to the enclosure via, for example, one or more fasteners. In one example embodiment, the DIN rail 132 can be coupled to the base plate 108 and thereafter the internal load switch 130 can be coupled to the DIN rail 132. Alternatively, the internal load switch 130 can be coupled directly to the base plate 108 without the intervening DIN rail 132. Additionally, the contact carrier bracket 102 can be coupled to the base plate 108 and thereafter the connector 120 can be coupled to the contact carrier bracket 102. The internal load switch 130 can also be electrically coupled or wired to the connector 120. In addition, PCB 106 may be coupled to the contact carrier bracket 102 and electrically coupled or wired to the connector 120 and/or internal load switch 130 as required. All of this assembly can be completed without the space constraints of the enclosure. Thereafter, once the components have been coupled to the base plate 108 and/or electrically coupled or wired to each other, the base plate 108 and the components mounted thereto can be positioned within the enclosure base 112 and one or more fasteners can be used to couple the base plate 108 to the enclosure base 112). In this manner the base plate 108 enables a stand-alone subassembly or module of components, including the load switch and others, to be assembled and/or wired together prior to positioning within the enclosure. The base plate 108 is arranged and configured as a platform for component assembly so that components and any electrical wiring can be assembled onto the base plate 108 without the enclosure base 112 sidewalls limiting access to connection and access points. Once completed, the base plate 108 and the components assembled thereto can be positioned into the walled enclosure and coupled thereto.
The base plate 108 may be manufactured from any suitable material including, for example, metal such as, for example, galvanized steel. As illustrated, the base plate 108 may have a rectangular shape although it is envisioned that the base plate 108 may have any other suitable shape and/or size. In addition, although illustrated as a single component, it is envisioned that the base plate may be formed of multiple pieces.
The mechanical interlock 100 may be adapted and configured with a particular connector 120 for receiving a corresponding plug. The connector 120, depending on the plug's configuration, voltage, etc., may have a different size and/or clock position. It is not uncommon for manufacturers to make and store a number of differently sized contact carrier brackets corresponding to a number of different connectors. That is, under current manufacturing techniques, a unique contact carrier bracket may be required for every unique plug and connector configuration. However, given their overall shape, manufacturing of contact carrier brackets can be complex and expensive. The adapter 104 therefore is used for operatively coupling the contact carrier bracket 102 to the connector 120, which receives the plug. In this manner, a single contact carrier bracket 102 can be manufactured, stored, and incorporated into every mechanical interlock regardless of which connector 120 is being used. Individual adapters 104 corresponding to each connector 120 can be manufactured and stored, and then, based on the required connector 120, the corresponding adapter 104 can be selected and coupled to the contact carrier bracket 102.
The depicted embodiment of contact carrier bracket 102 includes a first end for coupling to, for example, the base plate 108 or the enclosure base 112, and a second end arranged and configured for coupling to the adapter 104, which is arranged and configured to receive the connector 120. As illustrated, the second end may include first and second arms defining a space therebetween. The adapter 104 may be in the form of a ring having an outer circular shape and an interior opening. In use, the adapter 104 may be arranged and configured to be at least partially received within the space formed between the first and second arms, although it is envisioned that the adapters and the contact carrier bracket may take many different forms. The adapter 104 may be coupled to the contact carrier bracket 102 by any suitable mechanism (adhesive, bonding, etc.) and/or one or more fasteners. Thereafter, the connector 120 may be positioned within the interior opening formed in the adapter 104.
Each adapter 104 may be color coded, with each color corresponding to a specific connector 120, which adds a level of failsafe to the selection and assembly process. That is, as will be appreciated by one of ordinary skill in the art, plugs and their corresponding connectors 120 can be provided in any number of configurations. For example, different current levels (e.g., 16 amperes (A), 20 A, 30 A, 32 A, 60 A, 100 A, 150 A, 200 A, 400 A, or the like), different voltage levels (e.g., 125 volts (V), 240V, 250V, 480V, 600V, 100/130V, 125/250V, 102/208V, 200/250V, 208/250V, 277/480V, 346-415V, 347/600V, 380/415V, 440-460V, and others), and/or different ground pin locations (e.g., depending on the individual plug and connector, the ground pin, located in the connector, is positioned in a particular location along the circumference of the connector to ensure that the connector is only able to receive a corresponding plug, referred to herein as a “clock position”).
In use, each adapter 104 can be color coded to a specific connector 120 to ease selection of the correct adapter 104 so that, during assembly, depending on the configuration of the connector 120 being assembled into the enclosure, a color-coded adapter 104 can be selected thereby simplifying the assembly process and/or quality control verification. That is, the adapters 104 can be color-coded for a specific voltage and/or clock position.
Additionally, the adapter 104 and the contact carrier bracket 102 may include an alignment, key or keying feature (e.g., a Poke-Yoke mechanism) incorporated therebetween (alignment, key and keying are used interchangeably herein without the intent to limit) to ensure that the adapter 104 is properly positioned relative to the contact carrier bracket 102 when coupled thereto. In one example embodiment, the adapter 104 and the contact carrier bracket 102 include a first key to ensure that the adapter 104 can only be coupled to the contact carrier bracket 102 in a single, proper position. In use, the connector 120 and the adapter 104 may include a key incorporated therebetween to ensure that the connector 120 is properly positioned relative to the adapter 104 when coupled thereto. In one example embodiment, the connector 120 and the adapter 104 include a second key to ensure that the connector 120 can only be coupled to the adapter 104 in a single, proper position. In this manner, by keying the position of the connector 120 relative to the adapter 104 and by keying the position of the adapter 104 relative to the contact carrier bracket 102, proper positioning (e.g., proper clock positioning of the connector 120) is ensured. By preventing incorrect installation of the adapter 104 relative to the contact carrier bracket 102 and/or relative to the connector 120, incorrect final position of the connector 120 relative to the contact carrier bracket 102 is prevented. That is, the adapters 104 are preferably arranged and configured to ensure that the adapter 104, and hence the connector 120 received thereby, can only be coupled to the contact carrier bracket 102 in a single orientation (e.g., orientation can be defined by orienting the ground pin in the connector 120 relative to the contact carrier bracket 102 at a clock position such as, for example, 6 o'clock, 7 o'clock, or the like).
In use, the various keys may be arranged and configured so that if the connector 120 was improperly coupled to the adapter 104 such as, for example, the connector 120 was improperly rotated relative to the adapter 104, and/or the adapter 104 was improperly coupled to the contact carrier bracket 102 such as, for example, the adapter 104 was inserted in a flipped or reverse position and/or if the adapter 104 was installed in an incorrect rotational position relative to the contact carrier bracket 102, the keys will not align with the associated surfaces of the connector 120 and/or the carrier bracket 102, thus preventing incorrect coupling of the connector 120 to the adapter 104 and/or the adapter 104 to the contact carrier bracket 102.
It should be appreciated that numerous variations of keys may be utilized to ensure that the connector 120 can only be coupled to the adapter 104 and that the adapter 104 can only be coupled to the contact carrier bracket 102 in a single, proper orientation. As such, the keys may be any suitable mechanism or keying feature now known or hereafter developed so long as improper coupling and/or orientation of the connector 120 relative to the adapter 104 and/or the adapter 104 relative to the contact carrier bracket 102 is prevented. As such, the present disclosure should not be limited to any particular key described and illustrated herein unless specifically claimed.
In examples, the adapter 104 may include one or more male features, bosses, projections, or the like (used interchangeably herein without the intent to limit) and the contact carrier bracket 102 may include one or more female features, openings, holes, or the like (used interchangeably herein without the intent to limit), arranged and configured to mate with the boss formed on the adapter 104, or vice-versa. In this manner, the boss extending from the adapter 104 can only be received within the hole formed in the contact carrier bracket 102 when the adapter 104 is properly positioned relative to the contact carrier bracket 102, thus ensuring easy and failsafe assembly. That is, in this manner, each configuration of adapter 104 can only be installed in a single orientation (e.g., cannot be accidentally or unintentionally flipped and/or rotated, thus changing, for example, the clock position of the ground pin in the connector 120), thus, ensuring proper orientation and/or positioning of the adapter 104 relative to the contact carrier bracket 102, and hence proper positioning of the clock position or ground pin location of the connector 120.
In one example embodiment, the adapter 104 may include a first boss protruding therefrom and the contact carrier bracket 102 may include a first hole for receiving the first boss extending from the adapter 104. The boss and the hole may be arranged and configured so that the first boss is only receivable by the first hole when the adapter 104 is properly positioned and/or orientated relative to the contact carrier bracket 102. By providing a key, the adapter 104 cannot be incorrectly coupled relative to the contact carrier bracket 102. In use, the key may include different sized bosses and holes, different shaped bosses and holes, etc.
In one example embodiment, the connector 120 may include one or more features, recesses, flat portions, or the like (used interchangeably herein without the intent to limit) and the adapter 104 may include one or more features, bosses, projections, flat portions, or the like (used interchangeably herein without the intent to limit), arranged and configured to mate with a feature formed on the connector 120, or vice-versa. For example, the adapter 104 may include one or more projections extending inwardly therefrom for mating with one or more recesses formed in the connector 120. The projection may include a threaded bore for receiving a fastener for coupling the connector 120 to the adapter 104. In this manner, the feature formed on the adapter 104 can only mate with the feature formed on the connector 120 when the connector 120 is properly positioned relative to the adapter 104, thus ensuring easy and failsafe assembly. That is, in this manner, each configuration of connector 120 can only be installed in a single orientation (e.g., cannot be accidentally or unintentionally rotated, thus changing, for example, the clock position of the ground pin in the connector 120), thus, ensuring proper orientation and/or positioning of the connector 120 relative to the adapter 104, and the adapter 104 relative to the contact carrier bracket 102, and hence proper positioning of the clock position or ground pin location of the connector 120.
As previously mentioned, the mechanical interlock 100 may also include one or more PCBs such as, for example, PCB 106 coupled to the contact carrier bracket 102. The PCB(s) 106 may be coupled (e.g., mounted) to the contact carrier bracket 102 to provide an increased level of protection from, for example, the environment (e.g., water, etc.) and to provide an increased level of protection from damage associated, for example, with dropping the device, transporting, etc. That is, when coupled to the enclosure 110, the contact carrier bracket 102 may include a top surface, a bottom surface, and laterally extending sidewalls defining a recess. In use, the PCB 106 may be coupled to the bottom surface of the contact carrier bracket 102 within the recess in-between the sidewalls. In use, the contact carrier bracket 102 may include one or more features such as, for example, shelves, ribs, bosses, etc. to allow installation and support of the PCB 106. In use, the contact carrier bracket 102 provides protection to the PCB 106 from, for example, damage during assembly, wiring or installation, protection from accumulated debris and water, protection during transportation, etc. In use, the PCB 106 may be protected by the sidewalls of the contact carrier bracket 102. The sidewalls acting as strengthening or stiffening ribs for increased robustness of the bracket 102. As such, the PCB 106 may be protected and/or partially encased by the contact carrier bracket 102 thus protecting the PCB 106 from water, damage, or the like by forming a housing type envelope around the PCB 106.
The PCB 106 may be coupled to the bottom surface of the contact carrier bracket 102, and be sized and configured to fit within the space envelope formed between the sidewalls of the contact carrier bracket 102. In this manner, the PCB 106 can be protected by the contact carrier bracket 102 from, for example, environmental and physical damage, thus ensuring a more robust design. Additionally, the PCB 106 can be installed and wired to the contact carrier bracket 102 before final bracket 102 installation (e.g., facilitates creation of a sub-assembly), as described above. In addition, the PCB 106 may include one or more keys between, for example, the PCB 106 and the contact carrier bracket 102 to ensure installation in only one position, as described above.
These and other aspects are also described with reference to
Referring to
The mechanical interlock 200 may receive power through one or more power input conductors/lines (not shown) and may supply power to, for example, a plug coupled to the connector 220. The external handle assembly 240 is typically mounted on a front of the cover 214 and may be connected to the load switch 230 through, for example, the handle and switch shafts 252, 254 to operate the actuating mechanism of the load switch 230. In use, the external handle assembly 240 may be rotationally locked to the load switch 230. Here, a shaft coupling the two is in the form of a two-piece shaft so that the external handle assembly 240 may be operatively coupled to a handle shaft 252 and the load switch 230 may be coupled to switch shaft 254. The handle shaft 252 may be rotationally coupled to the switch shaft 254 so that rotation of the external handle assembly 240 rotates the handle shaft 252 which rotates the switch shaft 254 which rotates/actuates the load switch 230 to selectively supply and disconnect power from the connector 220 and hence the plug and the downstream electrical device.
As illustrated, the enclosure may be made up of a rear housing portion or base 212 and a front housing portion or cover 214, although it is envisioned that the enclosure may be manufactured from more or less portions. In addition, the enclosure may be manufactured from any suitable material including, for example, plastic, metal, or the like.
In use, the downstream electrical device may be energized or de-energized depending on the position of the handle assembly 240. Accordingly, the mechanical interlock 200 is “ON” (e.g., supplying power to the connected, downstream electrical device) when the plug is coupled to the connector 220 and the handle assembly 240 is in an “ON” position. When the handle assembly 240 is moved to an “OFF” position, the actuating mechanism of the load switch 230 will have been moved to open the contacts, so that power to the associated electrical device is disconnected. In general, the handle assembly 240 is rotated ninety-degrees to transition the mechanical interlock 200 between the ON and OFF positions.
The mechanical interlock 200 may also include an interlock latch assembly (not pictured) selectively movable between a first position and a second position, and, as described above, arranged and configured to be operatively associated with the connector 220 and the external handle assembly 240 so that when the interlock latch assembly is in the first position, the interlock latch assembly prevents rotation of the external handle assembly 240, and when the interlock latch assembly is in the second position, the interlock latch assembly permits rotation of the external handle assembly 240. The interlock latch assembly may be movable between the first position and the second position via insertion of the plug into the connector 220 such that insertion of the plug into the connector 220 contacts and moves the interlock latch assembly from the first position to the second position.
The PCB architecture 300 may be provided in any type of electrical device including, but not limited to, electrical switch devices (including, for instance, those with mechanical interlocks) described herein. The architecture 300 provides a unified and scalable approach for adding or removing electrical components that may operate within or as part of the electrical switch device. The architecture 300 provides connectivity to any type of constituent electrical component such as, for example, a sensor that may collect data that may be analyzed to facilitate predictive maintenance and improved performance of the electrical switch device and/or any other device coupled thereto. The architecture can be provided within electrical switches that are configured to operate in any of various three-phase configurations. As examples, in one embodiment, the architecture 300 can be provided within an electrical switch device that is configured to operate in a three-phase Delta configuration and in another embodiment, the architecture 300 can be provided within an electrical switch device that is configured to operate in a three-phase Wye configuration.
As shown in
The sensor hub module 308 may be any type of processing circuit (controller, processor, logic device, etc.) including, for example, any programmable logic device (PLD), application specific integrated circuit (ASIC), general purpose processor, or logic circuitry. In one embodiment, the sensor hub module 308 may be a microcontroller unit (MCU).
The power sensor module 302, temperature sensor module 304, moisture sensor module 306, and sensor hub module 308 may be interconnected by a communications bus 312. The communications bus 312 enables data or other communications to be transmitted between the power sensor module 302, the temperature sensor module 304, the moisture sensor module 306, and the sensor hub module 308. For example, data generated by the power sensor module 302 may be transmitted to the sensor hub module 308 over the communications bus 312. In one embodiment, the communications bus 312 may be a 2-wire isolated serial bus configured and/or operating according to the Inter-Integrated Circuit (I2C) protocol. In general, the communications bus 312 may provide connectivity with a reduced number of wires that isolates low voltage components of the architecture 300.
Each sensor within the architecture 300—for example, each of the power sensor module 302, the temperature sensor module 304, and the moisture sensor module 306—may generate a respective signal(s) indicative of detected conditions or collected data and may transmit the generated signal(s) to the sensor hub module 308. The sensor hub module 308 may then receive and process the signals. The sensor hub module 308 may then process and/or analyze any data provided in a signal provided by a sensor of the architecture 300. The sensor hub module 308 may adjust or control operation of any component of the architecture 300 or any other component coupled to the sensor hub module 308 based on the information provided by the received signals.
As an example, the sensor hub module 308 may transmit control instructions or other information to the power sensor module 302 based on data provided to the sensor hub module 308 from the power sensor module 302. Similarly, the temperature sensor module 304 and the moisture sensor module 306 may interact with the sensor hub module 308 to exchange data or other information. In this way, data generated by any of the power sensor module 302, the temperature sensor module 304, and the moisture sensor module 306 may be provided to the sensor hub module 308 and the sensor hub module 308 may direct operation of any of the power sensor module 302, the temperature sensor module 304, or the moisture sensor module 306.
The sensor hub module 308 may provide processed data to the communications module 310. The communications module 310 may transmit any information or data received from the sensor hub module 308 to any remote device, remote computer network, or remote cloud service or platform. The communications module 310 may provide a wired communications interface operating according to any known wired communication standard or protocol. The communications module 310 may also or alternatively provide a wireless communications interface operating according to any known wireless communications standard or protocol. In one embodiment, the communications module 310 may be a Wi-Fi module. In one embodiment, the sensor hub module 308 and the communications module 310 may communicate over a universal asynchronous receiver-transmitter (UART) connection. The communication may be according to any of various data communication protocols, an example of which is Modbus.
The communications module 310 allows data or other information provided to the sensor hub module 308 by the power sensor module 302, the temperature sensor module 304, the moisture sensor module 306 or any other constituent component of the electrical switch device coupled to the communications bus 312 to be offloaded for processing or analysis. Further, the communications module 310 allows data or other information (e.g., control instructions) from a remote device to be received and provided to the sensor hub module 308. The sensor hub module 308 may then direct operation of the power sensor module 302, the temperature sensor module 304, and the moisture sensor module 306 or any other constituent component of the electrical switch device coupled to the communications bus 312 based on data received from a remote device or network.
The architecture 300 allows the sensor hub module 308 to receive data from any number of components coupled to the communications bus 312. Further, the architecture 300 allows data provided to the sensor hub module 308 to be transmitted remotely to enable remote monitoring of the electrical switch device. An operational state of the electrical switch device may be determined by a remote device based on the provided data. Preventive maintenance of the electrical switch device may then be provided based on knowledge of the operating state of the electrical switch device. The architecture 300 also allows remote data or other remote communications to be received by the sensor hub module 308 and then distributed to any component coupled to the communications bus 312. In this way, the electrical switch device having the architecture 300 may operate as an intelligent device by interconnecting constituent components of the device and connecting the constituent components to a remote device, a remote device, the Internet, and/or a cloud service or platform. In turn, the connectivity provided by the architecture 300 may provide improved monitoring and maintenance of the electrical switch device or any constituent component thereof.
The operational status of the electrical switch device or any component thereof may also be indicated locally using light emitting diodes (LEDs) 314. The LEDs 314 may be, for example, positioned on an outer portion of an enclosure of the electrical switch device. The LEDs 314 may be operated to indicate an operation status of the electrical switch device or any constituent component thereof.
The architecture 300 may optionally include a liquid crystal display (LCD) module 316 (shown in phantom in
The architecture 300 provides an easily scalable and upgradable means to interconnect constituent components to the sensor hub module 308. A first additional sensor module 318 and a second additional sensor module 320 are shown in phantom to indicate the ability to enhance, augment, upgrade, or scale the architecture 300 to meet the needs of the user. The first and second additional sensors 318 and 320 may be added to the communications bus 312 to facilitate interconnectivity with the sensor hub module 308 without the need to add new or separate wiring or to implement additional communication technologies. In general, the architecture 300 allows for any number of components (e.g., sensors, displays, circuits, etc.) to be coupled to the communications bus 312. For example, multiple sensors of the same type (e.g., two or more temperature, humidity, or moisture sensors) may be coupled to the communications bus 312 and configured to communicate with the sensor hub module 308. Further, a variety of different types of sensors beyond those illustrated in
The moisture sensor module 306 may be or include a moisture detection sensor. By way of specific example, the moisture detection sensor may be or include a water detection sensor to detect water. Further description of the moisture detection sensor is provided by way of example with reference to a “water detection sensor”, though it is understood that these aspects may be equally applicable to any kind of moisture detection, not just water. A water detection sensor can detect accumulation of water inside enclosures containing high voltage circuits or wiring such as, for example, an electrical switch device. The water detection sensor may provide an alert or alarm if an amount of water inside of the enclosure exceeds a predetermined level, thereby enabling action to be taken to reduce the likelihood of compromised safety or equipment failure. The water detection sensor may be provided within or on a component of an electrical switch device, such as the enclosure or housing such that the water detection sensor is provided within or on a surface of the enclosure. In embodiment, the component may be a PCB such that the water detection sensor is provided on the PCB which may be mounted inside of an electrical switch device. In an embodiment, the water detection sensor may be provided within a device that is mounted on a wall with the water detection sensor oriented either vertically or horizontally.
The water detection sensor can generate and transmit a signal (for instance to a communication module) indicating that water inside of an enclosure in which the water detection sensor is positioned has exceeded a predetermined level. In embodiments, the signal may be an alarm signal and may be transmitted over any type of communication link including, for example, a wired or wireless communication link. In one embodiment, the water detection sensor may include or may be coupled to one or more LEDs that may provide a visual alarm regarding the detection of water that exceeds a predetermined level.
Cover subassembly 420 includes front cover 414, handle shaft 422, liquid sensor assembly 424, lens 426, magnet 428, stop plate 430, display board 432, communications board 434, heat sink 436, thermal pad 438, power PCB 442, and insulator 444.
The components of cover subassembly 420 when assembled are stacked and fastened (e.g. with screws) in/to cover 414, and handle assembly 440 is mounted on a front of the cover 414 (e.g. as in
The electrical switch device enables an operator to rotate the handle between ON and OFF positions to turn ON and OFF the internal load switch accordingly and control provision of power to the load. In addition, aspects of the electrical switch device can be used to inform end users of ON/OFF status, voltage/power presence (both load and line side), and possible issues related to, e.g., voltage imbalance of the electrical supply to the load connected to the device, or loss of ground. In these examples (e.g. in contrast to
Liquid sensor assembly 424 can also be leveraged to inform end users about water (or other moisture) accumulation due to condensation, accidental water seepage, and the like. In embodiments, a visual indication (via the LED lights), communication to a remote device, or an alert/alarm can be presented in particular situations, such as when a particular water height is reached, as an example, thereby enabling action to be taken to reduce the likelihood of compromised safety or equipment failure. The user, once informed, has an opportunity to avoid an unsafe condition by opening the device and removing the water, for instance.
In accordance with aspects described herein, improvements of functionality and serviceability, including conversion of existing switch devices into smart switches, are achieved as described herein in part using mechanical and electrical PCB arrangements.
Referring again to
Handle shaft 422 includes another opening 462 at the central axis 463 of handle shaft 422. Opening 462 is configured to accept one end of the switch rod 450 to operatively couple with the switch rod 450 so that the two are rotationally locked, i.e. rotation of handle shaft 422 rotates switch rod 450.
Opening 429 for the magnet 428 is offset from central axis 463 toward a periphery of handle shaft 422 in this example. With magnet 428 embedded at least partially within handle shaft 422, clockwise or counter-clockwise rotation of the handle shaft 422 about its central axis 463 will carry the magnet in a corresponding clockwise or counter-clockwise direction about the central axis.
As explained in further detail below, there is a corresponding magnetic field sensor 464 (see
Display board 432 may include various components. Example such components are an LED module with functionality that includes LED functionality described above, for instance to display visual information such as information regarding the operational status of the electrical switch device or any constituent component thereof. Additionally, as noted, the display board can an incorporate magnetic sensor 464 to sense a magnetic field of magnet 428.
Communication board 434 may be any type of PCB that facilitates communication between the electrical switch device and remote devices, as described herein. In examples, the communication board 434 is a WiFi chip/board and/or one that uses the Modbus protocol for communication. The communication board 434 can be used to notify remote devices (smartphones or other computer systems) and users thereof of any data collected or sensed by electrical switch device, including any information that may be indicated by the LED indications. In examples, the communication board 434 is mounted to display board, e.g. as a ‘daughterboard’ thereof (see
Heat sink 436 and thermal pad 438 cooperatively provide heat sinking for components of the electrical switch device, for instance PCBs thereof, e.g. display board 423 and power PCB 442.
PCB(s), such as communication board 434, display board 432, and/or power PCB 442, can implement aspects of a PCB architecture such as is described above with reference to
Insulator 444 provides an insulating buffer between the base subassembly 412, particularly the base plate 454 thereof (see
When assembled, the components of the cover subassembly provide a stacked display board (432) and power board (442) arrangement. This differs from other approaches, such as those described above with reference to
In accordance with these aspects, the communication board 434 is plugged into the display board 432. Other such ‘daughter’ boards providing differing functionality could also be coupled to display board 432, depending on what kind of interface or other functionality is desired. Accordingly, these other boards can similarly be incorporated into the stacked board arrangement of the cover subassembly 420, removing them from the base subassembly and enabling greater flexibility and options for serviceability and replacement of existing ‘dumb’ electrical switch devices to convert them into smart switch devices. In general, any PCB desired for features described herein could be provided in the cover subassembly such that the cover subassembly could work with a variety of existing or to-be-developed base subassemblies.
As mentioned above, the magnet 428 placed into the handle shaft 422 cooperates with the magnetic sensor 464 mounted on the display board 432 for the magnetic sensor 464 to provide an indication of the ON/OFF status/state of the device 400. Disposing the magnet 428 on or in a component that rotates with rotation of the switch handle results in selective positioning of the magnet 428 depending on the rotational position of the handle, which is tied to an ON/OFF status of the load switch on account of the rotational coupling of the handle to the load switch via shaft component(s). As described with reference to the stop plate 430, the design thereof can shield the magnetic field sensor 464 from the magnetic field emanating from the magnet 428, preventing the magnetic field sensor 464 from sensing the magnetic field depending on the position of the magnet 428 relative to the magnetic field sensor 464.
In this manner, the magnetic field sensor 464 can sense the magnetic field when the handle is in the OFF position (and therefore internal load switch 452 is open) and may be unable to sense the magnetic field—or senses it differently, for instance at a less intensity-when the handle is in the ON position (and therefore internal load switch 452 is closed) on account of interference imparted by the stop plate interposed between the sensor 464 and the magnet 428.
This configuration ensures that the position of the handle assembly 440 is known with certainty. The position of the handle assembly 440 as ascertained from the output of the magnetic sensor could be sufficient to conclude the state of the load switch (e.g. open or closed). This state can be compared, monitored, etc., and, if necessary, one or more fault indications can be provided. Optionally, this state could be compared to other indicators of the electrical state of the load switch 452 (e.g., ON versus OFF), and, if necessary, one or more fault indications can be provided. The magnet 428 may be a permanent magnet or the like that may be coupled to a rotating element (the handle shaft 422 as one example) that is directly tied in terms of its rotational position to the position of the external handle assembly 440 so that, in use, the magnet 428 can be moved into and out of sensing range relative to a magnetic sensor. The magnetic sensor is, for example, a hall-effect or other type of magnetic sensor 464. In some examples presented herein, rotation of the handle shaft 422 between first and second positions (e.g. corresponding to ON and OFF positions) moves the magnet 428 into and out of sensing range relative to the sensor 464 located on, for example, a PCB board 432.
When the magnet 428 is located at least a given distance away from the sensor 464, the magnet 428 may be out of a sensing range of the sensor 464 and thus the magnetic flux from the magnet 428 may be out of range from the sensor 464 and the sensor 464 will not detect any presence of the magnet. Then when the magnet 428 moves toward the sensor 464 on account of the rotation of, e.g., the handle shaft 422, to reposition the magnet relative to the sensor 464, the magnetic flux from the magnet 428 may be within a given distance or range of the sensor 464 to trigger the sensor 464 or otherwise be detectable to the sensor 464. The signal generated by the magnetic flux created when the magnet 428 is positioned within range of the sensor 464 can be transmitted to a processor (not shown) located on, for example, a PCB, such as the display board 432 or the power PCB 442, or on another PCB. The processor can then communicate the information to remote devices via the communication board 434. Optionally, if the load switch is capable of sensing and providing its state, the processor could be communicatively coupled to the load switch 452 and receive from the load switch a signal corresponding to the state of the load switch (e.g., ON or OFF). In this manner, the processor can receive data concerning the state of the load switch 452 such as, for example, whether power is being supplied and can compare the position of the handle assembly 440 (as informed by the magnetic sensor 464) to the electrical state of the load switch 452 to determine if one or more fault conditions exists, and if so, to provide an indication of fault. The indication could be provided by controlling ON/OFF state of one or more LEDs on the enclosure, or could be one or more wireless signals, texts, emails, or the like transmitted by the electrical switch device.
Additionally or alternatively, the stop plate 430 may be configured to shield the magnetic field sensor from the magnetic field emanating from magnet 428 depending on the position of the magnet, to enhance magnetic coupling/detection between the magnet 428 and the magnetic sensor 464 on the display board 432.
As noted, the stop plate 430 may be made of material with a shielding property that shields/blocks/masks a magnetic field from penetrating through the stop plate material. A stop plate with no opening may block the magnetic field from reaching the sensor altogether, regardless of the handle position, such that the sensor would not detect the magnet and therefore cannot distinguish between the handle positions. However, the opening 468 may be positioned and configured (i.e. size, shape, etc.), so that the shielding effect of the stop plate is ineffective to prevent the magnetic sensor from sensing the magnet in the first position on account of the opening 468 provided in the stop plate. The shape, size, and position of the opening can all influence the extent to which the magnetic field is able to pass through the opening. In embodiments, it is desired for the opening to be configured and positioned such that the magnetic field is sensed by the sensor when the handle is in the first position but not when the handle is in the second position.
When the handle 440 is to turned to the second position and the magnet 428 is out-of-alignment with the opening 468 of the stop plate 430 and positioned farther therefrom, the configuration of the stop plate 430 shields the magnetic field emanating from the magnet 428 from detection by the magnetic field sensor 464. For example, the magnetic field sensor is sufficiently shielded by the stop plate 430 (the magnetic field does not penetrate the stop plate material) and the magnet is sufficiently far enough away from the opening that the sensor cannot sense the magnetic field emanating from the magnet.
In these examples, the intensity of the magnetic field sensed by the magnetic sensor on the display board is greater when the handle is in the OFF position. In embodiments, when the handle is in the ON position, the magnetic sensor does not sense the magnetic field of the magnet or senses the field at a lower intensity than the intensity it senses when the handle is in the OFF position. Thus, with the handle shaft and therefore magnet in a first position (e.g., corresponding to the OFF position of the handle), the magnet may be positioned within a sensing range of the magnetic sensor so that the magnet interacts with the magnetic sensor such that the magnetic sensory provides a signal that the external handle is in the OFF position. With the handle shaft and therefore magnet in the second position (e.g., corresponding to the ON position of the handle), the magnet is moved counterclockwise so that the magnet may no longer be within range of the magnetic sensor and/or the magnetic emanating from the magnet may be sufficiently shielded by the stop plate, and therefore the magnet no longer interacts with the magnetic sensor, which thus provides no signal. Alternatively, it is envisioned that the magnet may be arranged and configured to interact with the magnetic sensor when in the ON position and not in the OFF position.
The magnetic sensing can be used to detect and inform of the position of the handle, which provides an indirect detection of an electrical connection of the load to the power source. This can be monitored to enable voltage measurements on the load side, for instance.
In these examples, the stop plate 430 does not rotate and it interferes with the magnetic sensor's sensing of the magnetic field of the magnet more when the handle is in the ON position than when it is in the OFF position. However, various embodiments can exist in which the magnet, stop plate, and/or magnetic sensor are disposed or positioned in different configuration(s) in which rotational movement of the handle causes a relative movement between two or more of these devices to enable the magnetic sensor to sense the position of the handle.
Therefore, components of the electrical switch device could be configured and disposed such that rotation of the handle between the first position and the second position causes rotational motion of the magnet and/or the magnetic sensor (i.e. one or both), in which the rotational motion repositions the magnet and the magnetic sensor relative to each other. The magnetic sensor can be configured to sense this repositioning and output a signal to a processing circuit indicative of a position of the handle. The processing circuit may be configured to interpret the signal to obtain/identify the position of the handle and therefore the electrical state (open/closed, or ON/OFF) of the load switch. In this manner, rotation of the handle imparts rotational movement of the magnet and/or sensor so that they become repositioned relative to each other.
In some embodiments, the magnet could be disposed anywhere on the handle side of the stop plate such that it rotates with rotation of the handle. An alternative to embedding the magnet in the handle shaft is to couple the magnet to (for instance dispose the magnet) in/on an end of the switch rod 450 that is accepted into an opening of the handle shaft 422. The switch rod 450, including its end engaged with the handle shaft, rotates with the handle shaft 422 when the handle is rotated, providing the rotational motion that maybe sensed by the magnetic sensor. Alternatively, in another embodiment the magnetic sensor is disposed on the handle side of the stop plate, the magnet is disposed on the load switch side of the stop plate, the magnetic sensor moves from one position to another with rotation of the handle, and thus the magnetic sensor is positioned relative to the magnet and opening such that the magnetic sensor is brought closer to the magnet and senses handle position on that basis.
Accordingly, the magnet may be coupled to a component (such as the handle shaft 422) that rotates with rotation of the handle, and alternatively the magnet may be coupled to a component the remains in a fixed position while the magnetic sensor is repositioned relative to the magnet when the handle is rotated. In yet other examples, the magnet and the magnetic sensor are both repositioned when the handle is rotated from a first position to a second position but the magnet and sensor move relative to each other such that the magnetic sensor can distinguish between the first and second positions.
In examples, the magnet coupled to a component by being at least partially embedded within the component (e.g. handle shaft). Additionally or alternatively the magnet could be fastened, adhered, attached, press-fit, fixed, etc. to the component, fully encapsulated within the component, or in any other way physically engaged, directly or indirectly, with the component such that they remain in a fixed position relative to each other.
Aspects of the above are facilitated in part by a stacked design of the heat sink 436 and associated components between the display board 432 and the power board 442 to sink heat.
Also visible in
In such a stacked board arrangement, the magnet, the magnetic sensor, and the PCBs (432, 442 here) are provided in a stacked configuration coupled together such that they are enclosed in front cover 414 of the electrical switch device when assembled as in
Additional or alternative to a magnet-based approach for sensing movement, motion, and/or handle positioning, and switch opening/closing based thereon, one option is to mount a mechanical switch on a PCB (such as one of the aforementioned PCBs) that can be actuated physically according to (i.e. to comport with) the handle position (e.g. ON of OFF). Additionally or alternatively, an optical-based interrupter switch could be used for sensing movement, motion, and/or handle positioning, and switch opening/closing based thereon.
Electrical switch devices described herein are capable of accommodating a current sensor that can sense current of the power phase(s), each corresponding to a carrier wire connected to the load switch, and provide to local component(s) of the switch device and/or remote devices the values representative of the amount of current flowing through each of the phase(s) during the operation of the load connected to the device.
Aspects of one embodiment of a current sensor are depicted in
The current sensor 1400 includes a two-piece plastic housing 1402 enclosing a current sense module that includes a current sensor PCB 1406, a wound toroid for each power phase (e.g., three toroids 1404a, 1404b, 1404c in this example), a connector port 1407 for accommodating a communication cable that couples to another PCB of the electrical switch device into which current sensor 1400 is incorporated, and mounting brackets 1408a, 1408b, 1408c (one for each wound toroid) mounted to the PCB 1406. Each mounting bracket is configured to maintain a respective toroid in a fixed position relative to the PCB 1406. The mounting brackets 1408a, 1408b, 1408c in this example are mounted to the PCB 1406 to extend substantially perpendicularly from the PCB such that they are positioned for the phase conductors to pass through the toroids in a direction parallel to the PCB (see
The current sensor 1400 senses current of the three (in this example) phases corresponding to carriers/wires, segments of which are shown as 1410a, 1410b, and 14010c in
The current sensor 1400 could be installed on the line side or the load side of the internal load switch. Thus, in one embodiment the wires 1410a, 1410b, 1410c are line wires/conductors and the sensor 1400 is installed between the power source and input terminals of the internal load switch. Alternatively, the wires 1410a, 1410b, 1410c are load wires/conductors and the sensor 1400 is installed between the output terminals of the internal load switch and the load.
In the depicted arrangement, the toroids and mounting brackets are vertically mounted to the PCB board 1406.
Another embodiment of a current sensor in accordance with aspects described herein is depicted in
A current sensor as described herein can be mounted in the enclosure of the electrical switch device in any of various positions.
Accordingly, provided is a current sensor optionally mounted on a DIN rail or other component of an electrical switch device and coupled to PCB(s) of the electrical switch device to sense and inform of current passing through any of multiple carrier wires coupled to the switch.
Current sensors as described herein could be applied to other electrical devices, for instance the electrical devices described with reference to
In embodiments, the electrical switch device communicates with one or more remote computer systems. User can utilize software installed on a user computer system, for instance a mobile application installed on a mobile device such as a smartphone, to access status information about the electrical switch device, for instance any information that may be conveyed by LED lights of the electrical switch device (e.g. voltage presents, ground presence, etc.). The LED lights could provide an indication of current sensed for each power phase(s) entering of the switch, and this status information could be also communicated via one or more remote computer systems to a user application (e.g., mobile app) via the communication board 434. The user can use the user application to monitor the status of current passing through the individual power phases. As an enhancement, the user application could be configurable by the user to raise alerts (notifications, text messages, sounds, etc.) based on set pre-configured current thresholds that the user configures.
Provided is a small sampling of embodiments described herein:
Although various examples are provided, variations are possible without departing from a spirit of the claimed aspects.
The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising”, when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components and/or groups thereof.
The corresponding structures, materials, acts, and equivalents of all means or step plus function elements in the claims below, if any, are intended to include any structure, material, or act for performing the function in combination with other claimed elements as specifically claimed. The description of one or more embodiments has been presented for purposes of illustration and description, but is not intended to be exhaustive or limited to in the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art. The embodiment was chosen and described in order to best explain various aspects and the practical application, and to enable others of ordinary skill in the art to understand various embodiments with various modifications as are suited to the particular use contemplated.
Filing Document | Filing Date | Country | Kind |
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PCT/US2022/011524 | 1/7/2022 | WO |